Electric welding



Nv. 11, 1941. G, s. MIKHALAPOV 2,262,693

ELECTRIC WELDING Filed Aug. '7, 1959 2 Sheets-Sheet 1 ,F7/ci, c/Q, Y

j imn@ Nov. 11,. 1941.

G. S. MIKHALAPOV ELECTRIC WELDING Filed Aug. 7, 1939 2 Sheeyts-Sheet 2 rcap?" J: Md/d ov andra/jj j 4f /7//5 TfsAA/e'y lPatented Nov. i, lt?.

2,262,6idfi ELECTRIC WELDING George S. Mikhalapov, Philadelphia, Pa., assigner to Rustless Iron and Steel Corporation, Baltimore, Md., a corporation of Delaware Application August 7, 1939. Serial No. 288,888

3 Claims.

My invention relates to the welding of alloys, and more especially to the welding ofheat-hardenable alloy irons and steels, particularly the airhardenable stainless irons or steels.

One of the objects of my invention is to spotweld alloy products in a simple, rapid and efficient manner to achieve a product with welds of uniform high strength and ductility.

Another object is to spot-weld air-hardenable alloy irons and steels, especially the air-hardenable rustless irons and steels, in such manner as to achieve strong, tough and ductile welds of high durability and impact value, and which are substantially free from brittleness.

Another object is to produce welded products which are strong, ductile and free of brittleness by a spot-welding fabricating process which is characterized by the absence in the region of the weld of dendritic crystal structure.

Other Objects will be obvious in part, and in part pointed out hereinafter.

'I'he invention accordingly consists in the several steps of operation and the relation of each of the same to one or more of the others, the scope of the application of the invention being indicated in the accompanying claims.

In the draw ings, Figures 1 through 8 inclusive are photomicrographs of spot-welds illustrating certain features of my invention.

As conducive to a better understanding of my new invention, it may be noted at this point that there are number of alloy irons and steels and other alloy metals which are so sluggish in their actions that cooling merely from welding temperatures will cause them to harden at the weld. I intend to cover not only those steels which owe their peculiar properties to the presence of one or more elements` in addition to carbon, or to the joint action oi" such elements and carbon, which render them hardenable in air, but also those other steels and metal alloys which have the property of hardening during spot-welding operations.

Typical of the air-hardenable alloy steels are the stainless irons and steels wherein there is employed a chromium content ranging from 12%, or less, up to as much as 30%, perhaps with nickel additions up to as much as 2%. In such cases, carbon is present up to say 0.30%, the value of carbon generally being high for the higher chromium contents, Where the higher chromium contents are employed, nickel and carbon usually Y are present to assure hardenability and strength.

Molybdenum also may be present, especially in the steels of the higher chromium contents, in

amounts up to ser 2%.

The manganese content of the hardenable stainless steels preferably is kept low, because of the tendency of this metal to cause embrittlement. The silicon content likewise is ordinarily maintained at low values because of the embrlttling tendencies of this ingredient. In no case should the content of either of these twov ingredients exceed about 1%. Manganese, which participates in the hardening action, is now used to the extent of 0.80% in a typical 12% chromium steel, Itis to be understood, however, that the examples glv en are purely illustrative of a typical sluggish, air-hardenable alloy steel, and are by no means intended as being all-inclusive.

Now outside of the field of air-hardenable steels there are many steels which are normally considered to be only water or oil-hardening, that is; requiring a more rapid quench than air. A number of these steels, altho not air-hardenable, are

found to be hardenable when subjected to cor:- ventional spot-welding practices. This is due to the high rate of cooling which occurs at the weld. a phenomenon which occurs for reasons which will be pointed out hereinafter. Particularly is the hardening action emphasized when the spot- Welding electrodes are allowed to rest or dwell on the meta? following the passage of welding current, the electrodes thereby rapidly conducting heat away from the metal and chilling and hardening it. This phenomenon has made known spot-welding techniques unsuitable for such steels., as well as those steels known to be airhardenable.

Accompanying the hardening of the Wehl-hardn enable steels, there is a tendency towards embrittlement. This is especially pronounced in known spot-welding practices and appears to vary with the composition and properties of the metal undergoing treatment. It is so severe in the case of some metals that it has hitherto beer.` considered to be impossible successfully to spot-weld them. Investigation of these steels, alter they have cooled following the usual spot-welding operation, shows that the weld bead is extremely dendritic with coarse grains progressing perpendicularly from the contact faces of the pieces welded. The weld bead is hard and brittle., as contrasted with the desired tough, ductiie and small-grained structure of the parent metal back from the weld.

The brittleness attending the spot-welding or' certain alloy steels in the conventional manner has been found to manifest itself in any one 0r more of several diii'erent ways. A decrease in the impact strength of the weld is observed. Also there is a decrease in the static tensile strength, especially where the stress is applied perpendicularly to the plane of the weld, that is the weld faces. In extreme cases, actual cracks in the weld metal are noted. Apparently, these form either during the cooling following the welding step itself, or shortly thereafter.

Brittieness and low ductility are manifested not only by the metal of the weld itself, but also, in some cases, by the parent metal immediately adjacent the weld metal, that is to say. in the general region of the weld. When the weld metal alone is brittle, greatest dimculty is experienced when the sections of metal welded are of such rigidity and stiffness as to resist distortion when stress is set up in the weld metal, that is when the thickness of the metal sections exceed some 0.050 inch to 0.062 inch. In such instances the resistance to distortion of the parent metal is such that when stress occurs in the weld metal, there is a tendency for separation at the weld, this failure taking place through the weld 'at the plane of contact of the sections welded. When both the weld metal and the adjacent parent metal have become embrittled, then even in the case of metal sections of light gauge, where normally all distortion under stress would lie outside the weld metal, failure is frequently encountered, due to the varying stresses encountered in actual practical use.

Prior investigations lead to the conclusion that the conventional variations of welding technique, such as random alteration of the time of the weld, the intensity of the current employed, and the pressure of the welding electrodes, does not vary appreciably the degree or extent of weld embrittlement. Little benefit was had through flattening the temperature gradient between spot-weld and surrounding metal by preheating the adjacent metal. In addition, it did not appear to be practical to raise the temperature of the adjacent metal an amount sumcient to diminish the embrittlement eifect of the weld treatment.

Because of the importance of spot-welding as a method of fabrication an important object of my invention is to avoid the disadvantages of known spot-welding technique as applied to the weld-hardening alloy steels, and to evolve a technique which produces a strong, tough and ductile weld in a simple, rapid and direct manner, employing welding equipment of a rugged and comparatively inexpensive character.

In accordance with my invention I have found that weld embrittlement is due, at least in part, to the formation of a coarse-grained dendritic structure in the neighborhood of the weld. I have found that an improvement in the weld is realized, both in cases where the hardening occurs in the parent metal, as well as when it occurs in the weld itself, when eiforts are made toward increasing vastly the temperature gradient between the molten weld metal and the adjacent parent metal. Such efforts result in limiting the total amount of energy dissipated in the parent metal. A limitation in this energy minimizes the heating enect on the metal adjacentto the weld, and consequently minimizes the total volume of parent metal reaching the temperature necessary for the hardening phenomenon. In other words, where the total heat energy absorbed by the weld metal during the process of melting is dissipated in the parent and electrode metal without raising an appreciable part of the parent metal to the critical temperature, there is no substantial hardening of the metal adjacent the weld. Although this ideal condition is not fully reached in practice, I find that from a practical standpoint. a very satisfactory approach to it is made by greatly increasing the electrical power at which the spotweid is formed. 'I'his is had through greatly increasing the weld current and at the same time greatly decreasing the time of current flow.

In accordance with my invention, I tlnd that when the growth of the large-grained dendritic crystals is inhibited in the first place, confining the weld bead insofar as possible to a small grained equi-axed pearlitic crystal structure, the

f bead has substantially the same strength and ductility as the surrounding parent metal. 'I'he necessity for any after-treatment is avoided. It will be understood, however, that a heat-treatment may be employed where desired.

I have discovered that a highly satisfactory weld can be produced between sections of weldhardenable alloy metals, by passing therethrough an electric current of high intensity for an interval just sumcient to bring the metal sections to welding temperature. Where, at the same time, the duration of current application is kept suiiiciently short to ensure that the time interval of high temperature maintenance at the weld is insuicient to foster the rapid crystal growth which is encountered at such temperatures, the resultant weld is found to be characterized by the absence of dendritic structure. A weld produced by my new technique exhibits markedly advantageous qualities of strength, touchness, and ductility. It is evident, therefore, that the development in spot-welding of a method of producing a proper crystal structure in the region of the weld is of great importance.

In the practice of my invention, I prefer to piace the electrodes in opposition to each other. one on each side of the sections to be welded. While any suitable welding electrodes may be used. I choose to employ electrodes 'of one and a quarter inch diameter, having rounded contact ends, which are turned about a radius of say three inches. 'Ihese electrodes are forced with considerable pressure against the sections to be welded, preferably in th neighborhood of at least 1000 pounds. The resultant contact area is found to be about 0.032 square inch. Simple calculation, therefore, shows the pressure density is` of the order of 31,000 pounds per square inch. I have found that for different desired current values, depending not only upon the intensity with which it is desired to carry out the welding step but also upon the metals undergoing treatment and the dimensions of the sections to be welded, the pressure with which the electrodes are applied against the work may be varied within certain limits. This is desirable in order to lower the electrical resistance of the weld.

The high mechanical pressures with which the electrodes are applied to the metal strips or sections to be welded have the effect of reducing the surface electrical resistance, or contact resistance, between the metal lsections themselves as well as the resistance between the metal sections and the electrodes. This facilitates the passage of current through the region of the weld. For a given impressed voltage, the weld current will be increased upon an increase of pressure. In low impedance welding equipment, this increase is substantial although in the'high irnpedance equipment, the change is almost imperceptible.

In accordance with my invention', the weld current is permitted to flow for but a very brie! interval. In welding .030 inch sections best results are had with a current flow of from one- Yhalf to one cycle of a sixty-cycle current (that is to say, for from 1,520 to 1/,0 of a second). For heavier sections, a longer current dwell is permitted, while for lighter sections, a shorter dwell is desired. The use of intense welding currents for such short welding periods gives highly satisfactory welds. The weld bead is of a ilne even grain structure. The grains are substantially equi-axed. Dendritic crystals, if present at all in such welds, are found to be conilned substantially to the outer fusion zone.

While the duration of the passage of the current across the electrodes has been measured in the foregoing in terms of the number o! cycles of sixty-cycle welding current, it is apparent that 25-cycle, l5-cycle, direct current, or any other suitable welding current may be employed. The criterion is that the passage of a sunlciently high current, with suilicient pressure of the electrodes on the weld section, endures for a length o! time sufiicient to raise the Weld section to the welding temperature, yet insuiiicient to permit the development of appreciable dendritic structure. Experience has shown that this time interval ranges approximately between 17520 of a second and M30 of a second; at least it is preferably less than 1/(50 of a second.

Reduction oi time of current dwell below 1/2 cycle, in the case of sixty-cycle current, was found to be impractical, inasmuch as extreme difficulty was encountered in raising the metal in the region of the weld section to fusion temperature, even when very high electrical currents were employed.

The current required, in order to ensure the production of suihcient heat throughout the weld section, must vary inversely in proportion to the duration or dwell of the welding current. Thus, with a current dwell of say only l/2 a cycle, the current must be substantially higher than that required for a one cycle dwell, in order that the desired quantum of electricity may be passed through the weld section. As has been suggested in the foregoing, where the pressure at which the electrodes are applied to the metal strips is increased, then the current at a given rated voltage likewise is increased.

From my investigations oi' the loading conditions under which embrittled spot-welds fail in practice, I conclude that these are primarily due to static shear and to fatigue, or repeated-loading. Rough handling, sudden blows or shocks, or accidental impacts may impose other stresses, for example, impact shear or tension. These stresses are found to combine in unpredictable ways. I have found, however, that a static tension test is an entirely satisfactory measure of the toughness and ductility of a spot-weld, and so I have employed this simple test for determining the criteria by which the success of my new method is measured. This static tension test, of course, is one in which the weld is pulled apart by the steady application oi' a force along an axis normal to the plane of the weld, that is normal to the contacting surfaces oi' the welded sections.

Comparative experimental dataA on a number of welds made en sections of air-hardenable stainless steel strip are presented below in Tables I and II.

Tsar.: I

Single spot-welds on 0.030 inch sections of stainless steel strip analyzing chromium 12.48%. nickel .59%, molybdenum 0.41%, manganese 0.75%, silicon 0.44%, carbon 0.06% with the balance iron having a. hardenability of about 326 Brinell. Sixty cycle alternating current is used. Electrodes are copper 11/4 inches in diameter with ends rounded at a 3 inch radius.

Current Electrode Current S imen dwell in pressure 1n poc cycles i amps pounds l 13, 500 1,'000 1 15, 000 l, 100 l 16, 5(1) l, 000 l 18, 000 1, 500 24, 500 l, 250 27, (D0 2, 300

TABLE II Tests on the welds of Table i' Static 153:? Diameter Specimen tension, 'oop weld in pounds pounds inches 532 7. 8 398 9. 0 609 460 8. 4 About .185

480 11. 2 480 eis 40 .193 zo .aus

Careful consideration of the data of Tables I and II shows that excellent welds are obtainable, without the necessity of subsequent treatment, by current dwells of but x/2 to 1 cycle, sixty cycle current being assumed. All of the 1 cycle welds made with currents ranging from 13,500 amperes to 18,000 amperes, and with pressures ranging from 1000 pounds to 1500 pounds, developed consistently improved physical properties. Simple calculation based on the size of the weld bead and the weld current employed shows that the density of the welding current ranges upward from 557,000 amperes per square inchfor specimen 609, to values approaching one million amperes per square inch for some of the other specimens.

The 1/2 cycle welds, made at current values ranging from 21,000 amperes to 27,000 amperes, and at pressures ranging all the way from 1250 pounds to 2300 pounds, displayed marked variations depending upon the particular practice controlling their formation. Such welds are unquestionably superior when the higher currents and electrode pressures are employed. In point oi' fact, weld beads formed at 1/2 cycle, at currents of 27,000 amperes and with electrode pressures of 2300 pounds, as established in connection with specimen 614 of Tables I and II are found to exhibit the greatest strength. The investigations indicate that use of the lower currents and pressures result in incomplete fusion.

It is to be noted from a consideration of 5 Tables I and II that the V3 cycle welds, made at In this connection it ls signicant that these' larger diameter welds, produced at 1/2 cycle produce the best physical properties.

A summary of the data presented in Tables I and II shows that the l cycle dwells produced welds ranging from 384 pounds to 532 pounds i static tensile strength, with an average of about 450 pounds, or 16,300 pounds per square inch; while the V2 cycle welds ranged from 344 to 654 pounds, with an average of 530 pounds, or slightly arcanos `weld, 9000 amperes were passed between the electrodes for a 4 cycle dwell. Static tensile strength was found torange from 250 pounds to 300 pounds as noted above in Table III. The striking growth oi' long-grained, dendritic crystal structure, with sharp line of demarcation between the metal strips, is to be noted. The

less than 15,000 pounds per square inch. The i impact resistance is found to range from 7.0 to 12.0 foot pounds, with an average of about 9.5 foot pounds. Just as would be expected, the highest impact values are obtained rwith the higher electrical currents and higher electrode pressures. f

To contast sharply the desirable results of my short dwell-high current practice with the conventional longv dwell low current methods hitherto used, referenceis made to Table III clearly showing the greater strength of the welds made in accordance with my invention.

TABLE III Welding conditions Static tension Current ggg Time- Weld in ammoe in current diameter Pounds Pounds/sq. in. peres ohms. cycles in inches i 9,000 .(1)013 4 .18 250-300 9, S20-11,800 l5, 000 000107 l 18 400-450 15, 750-17. 700

Estimated approximate values.

An explanation of the superior results had in accordance with my invention is found in the accompanying drawings, wherein Figure I'illustrates, at a magnification of diameters, a longitudinal cross-section of a spot-weld of 0.18 inch diameter, produced by a 1 cycle dwell at a current of 15,000 amperes. -This specimen, of good strength and toughness, displayed a static tensile strength of 400-450 in Table III. Figure 3 is a photomicrograph of the mid-section of the same specimen as Figure 1, but magnied to 200 diameters.

These two figures illustrate the line-grained equi-axed crystals composing the greater extent of the weld. The duration of the dwell was so brief that dendritic growth was inhibited in all portions of the weld except at the outer fusion zone. The interlocking nature of the crystals is evident from Figure 3. The weld of these two gures displays a toughness and structure resembling that of wrought or heat-treated steel. A photomicrograph of a section of a satisfactory weld produced at a 1/2 ,cycle dwell would show the crystals approaching the point of virtual disappearance.

The small, interlocking grains of the weld of Figures 1 and 3 are to be contrasted with that depicted in the photomichrographs of Figures 2 and 4, for a specimen of low strength and toughness, formed by the conventional low-current, long-dwell method. Welds of such character are both weak and brittle. In the production of this pounds as reported and brittle welds may be crystal structure of this specimen is similar to that of cast'metal.

A comparison of the mode oi' failure of tough had by reference to Figures 5 and 6 on the one hand, and Figures-7 and 8 on theother hand. In the weld of Figures 5 and 6, produced according to my new high current-short dwell practice, the weld itself did not fracture. Rather, failure occurred in the surrounding parent metal. In the weld of Figures 7 and 8, however, the conventional lowcurrent long-dwell practice is represented. Here failure at low stress occurred in the weld. the weld, due to its brittleness, being completely torn out of the surrounding parent metal,

Thus, according to my new method of spotweldingemploying short dwell and high electrical currents, the various objects of my invention, together with many thoroughly practical advantages, are obtained. Vastly increased and 1 advantageous properties of strength, toughness and ductility are impaired rto the weld. Moreever, it becomes possible to weld successfully many alloy steels which have hitherto been considered as being incapable of successful spotwelding due to their weld-hardening characteristics. My new technique can be utilized with either manual or automatic manipulation of the metal sections being welded. A series of spotv welds may be made rapidly and eillciently.

`ent. From a practical Very little additional equipment'` is required. The invention, therefore, is characterized by its extreme simplicity, emciency, and economy.

Metal sections of all sorts may be successfully spot-welded according to my new technique. 'I'hese include sheet, strip, thin plate and the like, as used, for` example, in the fabricated parts of aircraft. The sections may be as thin as say 0.009 inch, or they may be ofv more important dimensions, that is, extending to the thickness limit for sheet and strip of 0.141 inch. In the c ase o f heavier gauges, the electrical energy supplied to the weld is increased to compensate for the additional heat losses resulting from the greater dissipating mass of metal which is presstandpoint there is little difilculty in bringing the metal to Welding temperature, since even with available equipment it is feasible to use electrical currents as high as 100,000 amperes or more.

As many possible Aembodiments may be made of my invention, and as many changes may be made in the embodiments hereinbeforeset forth, it will be understood that all matter described herein or shown in the accompanying drawings, is to be interpreted as illustrative, andnot as a limitation.

I claim:

1. In the spot-welding of sluggish, weld-hardenable ferritic and martensitic alloy steels, the art of producing a strong, tough and ductile welded junction .between metal sections of the tween the electrodes of 13,500 amperes or more for approximately 1/00 of a second or less, giving a current density of 500,000 amperes per square inch or more for a time sumcient to ensure fusion `:L f:',ween the metal sections in the region o1 the weld, but of duration so short as to inhibit effectively the development of dendritic crystal structure in that region.

2. In the spot-welding of sluggish, weld-hardenable ferritic and martensitic alloy steel sheet and strip, the art of producing a strong, tough and ductile Welded junction between metal sections, which comprises applying electric-current carrying electrodes on opposite sides of the metal sections at pressures of 1,000 pounds or more giving a pressure density of 31,000 pounds per square inch or more, passing l/a cycle to 1 cycle of 13,500 amperes or more of 60-cycle alternating electric current through the electrodes and through the metal sections between the electrodes giving a current density of 500,000 amperes per square inch or more for a time suillcient to ensure fusion between the metal sections in the region of the weld but of duration of application so short as to inhibit eiectively the development of dendritic crystal structure in that region, and give a grain structure at the weld of substantially equi-axed crystals.

3. In the spot-welding of sluggish, air-hardenable ferritic and martensitic stainless steels consisting of 12 to 30 per cent chromium, nickel less than 2 per cent, carbon up to 0.30 per cent and the balance substantially all iron, the art of producing a strong, tough and ductile welded junction between metal sections of the thickness of sheet and strip, which comprises the steps of, applying electric-current-carrying electrodes on opposite sides of the metal sections, at pressures ranging from approximately 1,000 pounds to approximately 1500 pounds, giving pressure densities of the order of 30,000 to 45,000 pounds per square inch, to decrease the contact electrical resistance, passing electric currents throughl the electrodes and through the metal sections between the electrodes, at values ranging from the neighborhood of 13,500 amperes to the neighborhood of 18,000 amperes, for approximately V60 of a second or less, giving current densities at the weld of 500,000 amperes per square inch up to about 1,000,000 amperes per square inch for a time sumcient to ensure fusion between the metal sections in the region of the weld, but so short as to inhibit effectively the development of dendritic crystal structure in that region.

GEORGE S. MIKHALAPOV. 

